CN113226935A - Method for manufacturing a package for flat panels and blank for said package - Google Patents

Abstract

Disclosed are a blank and a package for a flat sheet package and a method of manufacturing the same, the method comprising the steps of: -producing a foldable flat blank (B) made of packaging material, -folding the flat blank (B) to form a box-shaped package with an open closable flap, -introducing the flat panel into the box-shaped package and closing the closable flap, in the production step of the flat blank, the following steps are also provided: -feeding the web of wrapping material to a die-cutting and sorting unit (1) to obtain strips (C) parallel to the direction of travel₁‑C_n) -applying said strip (C)₁‑C_n) Punching and separating a plurality of elongated modular workpieces (P) therefrom₁‑P_n) -assembling said elongated modular workpiece (P)₁‑P_n) The modular pieces (P) folded into L-shape are brought together in pairs from a flat folded L-shape with their respective ends in correspondence₁‑P_n) Are fixed in such a way that the respective ends correspond, so as to form said blank (B) in the shape of a quadrangular frame.

Description

Method for manufacturing a package for flat panels and blank for said package

Technical Field

The present invention relates to a method of manufacturing a package for flat panels, a blank for such a package and a manufacturing plant therefor, in particular a method of manufacturing a package or box for wrapping flat panels such as ceramic tiles, slates, glass panels, laminates and the like.

Background

In industrial production lines, dedicated to packaging by means of cartons, the product units are packaged in cartons, which are usually obtained by bending die-cut paperboard. Die cutting techniques are widely used in the paper industry today to allow for the same and accurate cutting of special and complex shapes of paper, paperboard and similar materials.

The blank paperboard is usually die-curled or manipulated to obtain a flat tray (tray) with a suitably shaped profile, depending on the particular box size. On flat die-cut trays, creasing operations are carried out along specific lines, which allow a uniform and accurate folding of the flat material, due to the pressing of the paper or cardboard along predetermined folding lines.

In the last few years, the use of alternative techniques using boxes derived from traditional die-cutting techniques has become widely accepted in the packaging of flat products, in particular tiles, in the construction industry. In fact, it has been verified that, unlike the materials to be packed in bulk, piles of flat sheets of material (for example sheets, laminates and tiles) do not technically require complete containers: it is sufficient to have a package in which the various stacks of sheets can be mutually consolidated (consolidate) so as to protect only the sides and edges thereof. This allows saving a significant portion of the linerboard that would otherwise cover the sheet or tile surface without significant function.

This technique uses cardboard strips which are suitably cut and shaped in highly complex packaging lines in which cardboard bandages or containment frames are built around the stack of tiles.

Examples of this technique are exemplified in, for example, EP2952437, WO2016156928 and WO 2017149422.

The frame system represents an effective alternative to traditional pallet-shaped cardboard, with considerable advantages not only in terms of saving raw materials but also in terms of easy dimensional adaptability, resulting in a considerable reduction in the waste and stock of cardboard in the warehouse.

However, peripheral wrapping devices of tiles have significant inherent complexity-as they must create one complete wrap starting from a very simple cardboard strip, and they must simultaneously move along a line a series of heavy stacks of tiles around which the bandage is to be built-which makes them quite expensive. Moreover, they completely replace any traditional boxing lines pre-existing in the factory (i.e. those using classical die-cut trays), implying unpleasant dismantling of the previous investment items.

Therefore, there is a need for a packaging method and apparatus thereof that balances the advantages specific to perimeter frames with the relative savings in material and dimensional flexibility, while not wasting the investment already made for traditional boxing apparatus.

Disclosure of Invention

The object of the present invention is therefore to provide a solution to the above-mentioned problems and to provide a method and a plant for obtaining a simple and effective system for producing packages of stacked flat panels, which allows to save significantly material with respect to classic wrapping boxes, but at least partially utilizes traditional packaging machines using pre-die-cut trays.

According to the invention, this object is achieved by means of a method for producing a package for a stack of flat plates, such as ceramic tiles, having the characteristics defined in claim 1. Other preferred features of the invention are defined in the dependent claims.

Drawings

Further characteristics and advantages of the invention will be more apparent in any case from the following detailed description of preferred embodiments, given by way of non-limiting example and illustrated in the accompanying drawings, in which:

figure 1 is a schematic top view of a packaging blank production line according to the invention;

FIG. 2 is a detail view of FIG. 1 showing the unwind and continuous longitudinal cutting station;

FIG. 3 is another detail view of FIG. 1 showing a die cutting and grouping station;

FIG. 4A is a top plan view of an exemplary paperboard die cut workpiece (piece) obtained using the method of the present invention, and

FIG. 4B is a schematic top view of another exemplary mold;

FIG. 5 is another detail view of FIG. 1 showing a folding and preparation station for a single workpiece;

FIG. 6 is another detail view of FIG. 1 showing the assembly and bonding station of the blank;

FIG. 7 is another detail view of FIG. 1 showing an application station for applying corner protection;

FIG. 8 is another detail view of FIG. 1 showing the stacking and storage station; and

fig. 9 is a diagrammatic view of three representative photographs of three folding steps of a corner closure flap (flap).

Detailed Description

In a system for packaging flat panels, such as ceramic tiles, a traditional boxing line is advantageously used, in a manner known per se, in which flat blanks are folded and glued to form boxes in which stacks of flat panels are inserted before being properly closed. For this purpose, the boxing line comprises at least a folding device, a filling unit and a closing system of the upper flaps.

However, according to the invention, one or more conventional boxing lines are not fed with classic die-cut trays, but are preceded by an original blank production line, which will be disclosed in detail below.

As clearly highlighted in fig. 1, the blank production line according to the invention comprises a plurality of staggered stations intended to produce, starting from a flat material of standard shape (such as a paper roll or a sheet of suitable thickness, smooth cardboard, corrugated cardboard or the like), flat blanks having the original layout, which can be used in conventional boxing lines.

In the first drawing and unwinding station 1, a semi-finished flat packaging material C (e.g. thin corrugated cardboard) arranged in a supply unit 10 in the form of a stack or a spool of hexagonal accordion-shaped (corrugated cardboard) is drawn and conveyed to a line conveyor for processing.

In the case where the material is provided in the form of individually stacked sheets, downstream of the drawing station 1 there may be provided a joining station (not shown) having the function of joining two or more sheets in succession by gluing, for example using vinyl or hot melt glue: the purpose of this operation is to obtain a continuous flow of material when necessary. In this case, it is possible to provide a pressure section in the machine to locally compress the flat material to reduce the thickness of the overlapping area on the leading and trailing edges of the single sheet.

Just downstream of its drawing and the possible successive sheet joining, the flat cardboard material is cut in a longitudinal cutting unit 11. In this step, the continuous web of material (web) is divided into a plurality of strips C of the desired width₁To C_nPreferably an even number of bands C_nFor example six strips of uniform width. The strip C can be defined as desired₁To C_nFor example, by changing the distance between the axes of the cutting knives arranged in the station.

Then, atThe processing in the punching and sorting station 2 is divided into strips C₁To C_nTo form a flat semi-finished product. In such a station, die cutting is provided, possibly assisted by a transverse knife unit (not shown) which is moved from the continuous strip C₁To C_nSeparating a plurality of modular belts or workpieces to a desired length of appropriately shaped P₁To P_n. The modular pieces P can be easily changed by varying the intervention speed of the die-cutting and/or of the transverse cutter separating the individual pieces from the continuous material during the continuous sliding movement of the flat material C along the line₁To P_nLength of (d).

Preferably, also for example by following the workpiece P₁To P_nTo simplify the work pieces P by simultaneously performing operations of defining folding lines, in particular by creasing or cutting short, rectilinear, discontinuous cuts along longitudinal and oblique lines in the region of a centreline dividing each work piece into two parts₁To P_nFolding of (2).

Each modular workpiece P₁To P_nProvides a generally rectangular shape with a wide rectangular cut C near the mid-length of the workpiece (as shown in fig. 4A and 4B)_FRectangular incision C_FFrom the longitudinal edge until beyond the centerline longitudinal axis of the modular workpiece. Rectangular cut C_FTo modularize a workpiece C_nIdeally into two opposite branches C of length proportional to the two sides of the panel to be packaged_A1And C_A2。

Two opposite appendages or flaps C_EFrom one C of two opposite branches_A1A projection extending substantially on a longitudinal central axis of the modular workpiece.

In the cutting operation carried out in the blanking station 2, the strip C₁To C_nShaped to have the shape of the respective modular workpieces (fig. 4A and 4B), preferably operating so as to apply a specific pattern to one half of the modular workpieces arranged on one side of the longitudinal axis of the line and to apply a mirror image to the other half of the modular workpieces symmetrically arranged on the other side of the longitudinal axis of the lineAs shown in detail in figure 3.

At the end of the blanking, the modular pieces are then paired in mirror image P₁P_n、P₂P_n-1、P₃P_n-2.., and is arranged two forward along the conveying line (see the right-hand part in fig. 3). Substantially all of the modular workpieces P₁To P_nAre sorted only on two front runs so that they remain in parallel mirror pairs, intended to cooperate in a complementary manner.

A printing station (not shown) may be provided along the front, wherein a printing press is provided in the printing station, which applies text, logos and other graphic representations to the individual modular workpieces.

Downstream of the blanking and sorting station 2, the individual modular workpieces may be collected in an auxiliary buffer zone (left part of fig. 5) outside the preceding run, in which a suitable collector is provided for storing the workpieces waiting for the subsequent processing unit. The operating process module is then ready to reintroduce the mirror image and complementary pair of modular workpieces to a subsequent process unit at an appropriate speed.

In the consolidation station 3, pairs of complementary modular workpieces P₁To P_nIs processed in the folding unit 31. In particular, each modular workpiece is then brought along with the cut C_FA diagonal fold of about 45 ° arranged in the corresponding intermediate region, so as to make each workpiece P_nTwo opposite branches C of_A1And C_A2From a longitudinally aligned state to an orthogonally opposed attitude, i.e. one branch is at 90 ° relative to the other (as highlighted in figure 5).

As indicated above, the fold lines may be predetermined by means of creases or discontinuous cuts.

Folding is performed so that the cut portion C_FMaintained in orientation by each workpiece P_nTwo branches C of_A1And C_A2The outer sides of the formed corners are open.

Each of the modular workpieces exhibits an L-shaped profile and, since they have been previously arranged in mirror image pairs, they eventually form complementary L-shaped pairs, as shown in fig. 5. Therefore, they are arranged to be placed adjacent to each other corresponding to the respective ends to form an ideal quadrangular frame.

Two complementary modular workpieces P₁And P_nAfter being placed adjacent to each other and possibly partially overlapping in correspondence of the respective ends, is then firmly fixed in the assembly and consolidation station 4.

The fixing between the two L-shaped modular pieces is generally carried out by gluing the ends of each other in a manner known in the art at the point called G in fig. 6, preferably by means of hot melting so that the consolidation of the adhesive occurs in a short time after cooling.

As can also be clearly understood from the representation of fig. 6, the two modular, mutually welded workpieces form a final blank B very similar to a conventional tray-shaped die, wherein, however, only a rectangular frame with an open window in the middle is defined. Two branches C of modular workpieces by online modification_A1And C_A2The width and the length of the blank can be easily adjusted.

The final blank B forms a quadrangular flat frame of semi-finished material (for example corrugated cardboard), preferably provided with (creased or engraved) longitudinal folding lines, apt to subsequently perform the required folding. For example, two folding lines L are provided₁And L₂Carried out in the die-cutting and sorting station 2, it is then possible to fold 90 ° on each side of the frame of the blank along two fold lines for the first time to define a peripheral edge for housing the packs and then 180 ° for defining pack closure flaps for the second time.

It is possible to provide a further finishing station 5 (fig. 7) in which additional packaging protection is applied. In particular, at the vertex of the rectangular blank B (near the position where the blank material has a triangular cut, originating around the cut C)_FFolding the modular workpiece) may apply a filler element or patch R and a protective material, such as a polyurethane or polystyrene sheet. The patch R is joined to the cardboard material by gluing, stapling or other similar systems.

These corner protectors are intended to remain inside the package, abutting against the corners of the flat sheet to be packaged, thus protecting against impacts.

Finally, the blank B is sent to the stacking and storage station 6.

To this end, the blanks B may be supplied to a conventional boxing line, in which the blanks B are folded to form box-like packages, filled with stacks of plates and/or tiles, and then utilized with a predetermined closing line L₁And L₂And (5) closing.

In the folding step of such a box-shaped packet, it is also possible to use the flaps C_ETuck-in between the side flaps, while defining corner closures and inner reinforcing regions, protects the corners of the packaging material (see photos 1 to 3 in fig. 9).

The resulting box-like package actually covers and merges its contents (i.e. the stack of panels) mainly along the side edges and corners and the short peripheral strips on the top and bottom surfaces of the stack, however leaving a large portion of the larger surface of the panels uncovered, thereby saving packaging material.

In the following, for greater clarity, the method according to the invention briefly describes the complete packaging process.

In the first step of the packaging operation, the size of the pile of slabs to be packaged (for example, a batch of tiles) is checked, unless it is necessary to operate with standard products. Based on these dimensions, a plurality of blanks B, adjusting belts C are produced starting from the production line shown in FIG. 1₁To C_nCutting length and width of and incision C_FTo determine two opposite branches C_A1And C_A2Absolute length and relative length.

The production of the resulting blanks B starts and ends when the stacking station 6 receives an amount of blanks B sufficient to pack the provided batch.

The flat blanks B are then introduced into a feeder of a conventional boxing line, where they are folded to form box-shaped packages, and the flat sheets are then placed in the box-shaped packages before closing the packages.

As can be deduced from the description reported above, the solution proposed by the present invention perfectly fulfils the objects proposed in the preamble.

The production method of the packaging uses a continuous sheet semi-finished material, obtaining tray-shaped blanks sized and adjusted according to the requirements of the batch to be packaged, which makes the storage requirement for each specific box size superfluous.

The obtained blank is a solid product specifically conceived for packaging stacks, wherein the need of packaging is limited to reinforcing the various stack pieces and protecting the thin edges thereof, making it superfluous to cover the main surfaces of the stack, while in fact the packaging is devoid of material on the main surfaces of the stack for cost-saving benefits.

Furthermore, advantageously, the production line provides blanks perfectly compatible with conventional boxing lines that employ tray-shaped pre-cut blanks: this represents an important guarantee for the investment already made by the tile industry, since the production line of blanks can be assisted by the existing boxing machines without replacing it. Furthermore, the fact that the slabs are not transferred to the packaging line results in a lighter, cheaper and faster production line.

It is to be understood, however, that the invention is not to be considered limited to the particular arrangements described above, which represent only exemplary embodiments thereof, but that different modifications are possible within the reach of a person skilled in the art without departing from the scope of protection of the invention, which is limited only by the claims below.

For example, the shape of the individual modular workpieces may also be different from that shown to accommodate specific requirements relating to both the type of product to be packaged and the conventional boxing line employed.

Finally, although the packaging of stacks of flat sheets has been mentioned, it is not excluded that the method can also be used for packaging stacks of other large-surface products (which therefore do not require containment walls like those of the packaged products), such as trays (also concave) or slabs of various shapes.

Claims (10)

1. A method of manufacturing a package for a flat panel, the method of manufacturing comprising the steps of:

-producing a foldable flat blank (B) of wrapping material,

-folding the flat blank (B) to form a box-shaped package with an open closable flap,

-introducing the flat panel into the box-shaped package and closing the closable flap, characterized in that said step of producing a flat blank comprises the steps of:

-feeding the web of wrapping material to a die-cutting and cutting unit (1) to obtain strips (C) parallel to the direction of travel₁-C_n)，

-applying said strip (C)₁-C_n) Die-cut and cut from the strip (C)₁-C_n) Separating a plurality of elongated modular workpieces (P)₁-P_n)，

-assembling said elongated modular pieces (P)₁-P_n) From a flat fold into an L, bringing them close in pairs with their respective ends in a corresponding manner,

-said modular piece (P) to be folded in L-shape₁-P_n) Are fixed in such a way that the respective ends correspond, so as to form said blank (B) in the shape of a quadrangular frame.

2. Method according to claim 1, wherein the modular pieces (P) to be folded in L-shape are provided₁-P_n) The step of fixing the respective ends in a corresponding manner provides an adhesive step.

3. Method according to claim 1 or 2, wherein said folding operation provides each modular workpiece (P)₁-P_n) Folding along a diagonal of about 45 ° arranged in the middle region, so as to make two opposite branches (C) of each modular piece_A1And C_A2) From a longitudinally aligned state to an orthogonal relative orientation.

4. Method according to claim 3, wherein a plurality of elongated modular workpieces (P) is assembled₁-P_n) Said step of blanking provides for cutting said modular piece (P)₁-P_n) Shaped substantially as a wide rectangular cut (C) in the middle area_F) Is rectangular in shapeSaid rectangular cut (C)_F) Said rectangular cut (C) spanning from a side edge until it exceeds the longitudinal centerline axis of said workpiece_F) Joining the two opposite branches (C)_A1And C_A2) Apart, the respective lengths of the two opposite branches are proportional to the side edges of the flat sheet to be packaged.

5. Method according to claim 4, wherein said two opposite flaps (C)_E) From one (C) of said opposite branches_A1) A protrusion extending substantially on a longitudinal central axis of the modular workpiece.

6. Method according to claim 4 or 5, wherein the folding step is performed so that the cut-out portion (C)_F) Maintained in orientation by each workpiece P_nTwo branches (C)_A1And C_A2) The outer sides of the formed corners are open.

7. Method according to any one of the preceding claims, wherein said step of folding into an L-shape is preceded by the step of providing said elongated modular workpieces (P) also with a sheet of material₁-P_n) Upper defining a longitudinal fold line (L)₁And L₂) The step (2).

8. Method according to any one of the preceding claims, wherein there is further provided the step of applying an additional protector (R) in the vicinity of the vertex of the rectangular blank (B), said protector (R) being arranged on the side intended to be retained inside the package.

9. A flat blank for producing box-shaped packages, characterized in that it is formed from a pair of elongated modular pieces (P)₁-P_n) Of said pair of elongated modular workpieces (P)₁-P_n) Is folded in an L-shape and fixed with respective end portions thereof corresponding to each other to form a quadrangular frame.

10. Blank according to claim 9, wherein said elongated modular pieces (P)₁-P_n) Essentially having a wide rectangular cut (C) in the middle area_F) The rectangular cutout (C)_F) The rectangular cut (C) is crossed from the side edge until the longitudinal central line axis of the workpiece is exceeded_F) -shaping said elongated modular pieces (P)₁-P_n) Divided into two opposite branches (C) of length proportional to the sides of the panels to be packaged_A1And C_A2)。

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